Handle assembly for packages and method of making same

ABSTRACT

A handle assembly for a pourable package. The handle assembly attaches to a package having a front panel, a back panel, a bottom panel and opposing side gussets in which each side gusset has an inside wall and an outside wall. The handle assembly partially positions within an opening of the side gusset and partially positioned beyond the opening. The handle assembly comprises hand portions, each hand portion having a tab that extends beyond the opening and along the inside wall of the side gusset. The handle assembly further comprises a seal member positioned on the inside wall of the side gusset and around the opening wherein the seal member seals the tabs to the inside wall of the side gusset and seals the opening.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. § 119(e) of U.S. Provisional Patent Application No. 60/809,980 filed Jun. 1, 2006.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH

Not Applicable.

BACKGROUND OF THE DISCLOSURE

The present disclosure relates to handle assemblies for pourable packages. In particular, the present disclosure relates to handles attached to a side gusset of a package in the form of a flexible bag. The flexible bag can be plastic or paper. The present disclosure also relates to methods of attaching the handle assembly to the flexible bag.

The configuration of current handles for flexible bags results in inconvenient and inefficient handling or pouring of the bag's contents. Since these handles attach to sides of the bags, these handles tear away from the bag when the user pours contents from the bags as the content's weight applies a force to the interface of the handles and the bag. Furthermore, these handles provide edges at the bag interface that allow for contamination exposure to the bag's contents. It is imperative that bags retain a strong construction without any areas of contamination.

Additionally, current handles do not fold within the sides of the bag. As such, these handles remain exposed during non-use of the bag, such as during manufacturing of the bag or during storage of the bag, leading to tearing and/or fraying of the handles. Consumers need a handle that can be internally sealed to the gusset of the bag to assist in efficiently pouring contents from the bag without providing contamination exposure to the bag. Additionally, consumers need a handle that attaches to a gusset of the bag without tearing or separating from the bag as the contents pour from the bag or as the consumer holds the bag.

SUMMARY

The present disclosure relates to a handle assembly that internally seals to a side gusset of a package to assist in efficiently pouring contents from the package without providing contamination exposure to the package and without separating from the package. The handle assembly attaches within an opening of the side gusset.

The handle assembly comprises hand portions, each hand portion having a tab that extends beyond the opening and along an inside wall of the side gusset. The handle assembly further comprises a seal member positioned on the inside wall of the side gusset and around the opening wherein the seal member seals the tabs to the inside wall of the side gusset and seals the opening. The hand portions fold within the side gusset when the side gusset collapses to a retracted position and the hand portions extend beyond the side gusset when the side gusset opens to an expanded position.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

FIG. 1 illustrates a perspective view of a handle assembly constructed in accordance with and embodying the present disclosure, the handle assembly being attached to a side gusset of a package;

FIG. 2 illustrates an internal view of the handle assembly of FIG. 1 attached to the side gusset of the package;

FIG. 3 illustrates a side elevational view of the handle assembly of FIG. 1 illustrating a handle portion and illustrating a tab of the handle portion;

FIG. 4 illustrates a plan view of a pair of hand portions of the present disclosure attached to each other;

FIG. 5 illustrates another side elevational view of the handle assembly internally attached to the side gusset of the package by a seal member;

FIG. 6 illustrates a detail view of the tabs of the hand portions extending through and beyond the opening of the side gusset;

FIG. 7 illustrates a partial side elevational view of the of the tabs of the hand portions and the seal member;

FIG. 8 illustrates a plan view of the hand portions in a folded position over a segment of the side gusset;

FIG. 9 illustrates a side view of a user grasping the hand portions and pouring contents out of the package;

FIG. 10 illustrates a partial side elevational view of another embodiment of the handle assembly constructed in accordance with and embodying the present disclosure;

FIG. 11 illustrates a partial plan view of side gussets, an opening and a seal member of another embodiment of the handle assembly constructed in accordance with and embodying the present disclosure; and

FIG. 12 illustrates a partial side elevational view of the seal members of FIG. 11 attached to the package.

Corresponding reference numerals indicate corresponding parts throughout the several figures of the drawings.

DESCRIPTION OF THE PREFERRED EMBODIMENT

The following detailed description illustrates the disclosure by way of example and not by way of limitation. The description clearly enables one skilled in the art to make and use the disclosure, describes several embodiments, adaptations, variations, alternatives, and uses of the disclosure, including what is presently believed to be the best mode of carrying out the disclosure.

The terms “bag” and “package” are used interchangeably wherein the bag/package may comprise a rigid construction, a semi-rigid construction and a non-rigid construction.

Referring to the drawings, a package A in the form of a flexible bag 10 comprises a handle assembly 12 internally sealed to the flexible bag 10 (FIG. 1). The flexible bag 10 includes a front panel 14, a back panel 16, a bottom panel 18 and opposing side gussets 20. Each side gusset 20 further includes an inside wall 22 (FIG. 2) and an outside wall 24. Additionally, at least one of the side gussets 20 has a gusset opening 26 (FIG. 6) positioned therethrough. The flexible bag 10 and the handle assembly 12 may comprise a plastic material.

As shown in FIGS. 1 and 2, the handle assembly 12 comprises hand portions 28 and a seal member 30. Turning to FIG. 3, the hand portion 28 includes a top 32 with rounded corners 34 and a straight bottom 36. In an embodiment, the rounded corners 34 have a radius of curvature from about 0.8 inches to about one inch and the bottom has a measurement from about four inches to about six inches. Near the bottom 36, the hand portion 28 includes a tab 38 configured to fold outwardly with respect to the top 32 as will be discussed. Further, as shown, each hand portion 28 includes an opening 40 having rounded finger areas 42. In one embodiment, the rounded finger areas 42 have a radius of curvature measured from about 0.25 inches to about 0.50 inches. Additionally, each hand portion 28 includes a fold line 44 to allow the hand portion 28 to fold upon itself.

In one embodiment, the hand portions 28 utilize plastic film that is die-cut as illustrated in FIG. 4. As shown, the tops 32 of the hand portions 28 connect to each other. The film comprises a material strong enough to prevent ripping or tearing. In an embodiment (not shown), the film includes a coating on one side with a heat activated bonding layer. The hand opening 40 is cut within the hand portion 28 with the finger areas 42 at both ends. The top 32 of the hand opening 40 however is left uncut. By not cutting the top 32 edge, the handle assembly 12 is stronger and more comfortable to the user. Comfort is created with interior material of the hand portion 28 being folded over as the user's hand grasps the hand portions 28. The folded material prevents discomfort from a sharp edge if the hand opening 40 were to be totally removed.

Referring to FIGS. 5 and 6, the gusset opening 26 is defined through the centerfold of the side gusset 20 to guide the tabs 38 of the hand portions 28 within the flexible bag 10. The length of the gusset opening 26 may equal the length of the hand portion 28. As shown in FIG. 6, the handle assembly 12 partially positions within the gusset opening 26 and partially positions beyond the gusset opening 26. The tabs 38 of the hand portions 28 extend through the opening 26 and along the inside wall 22 of the side gusset 20. As shown, the tabs 38 outwardly extend from the opening 26 in opposing directions and along the inside wall 22 of the side gusset 20. In an embodiment, the tabs 38 extend along the inside wall 22 at a distance of about 0.25 inches to about 0.75 inches as measured from the opening 26. In another embodiment, the tabs 38 extend along the inside wall 22 at a distance of about 0.50 inches as measured from the opening 26.

The seal member 30 is positioned on the inside wall 22 of the side gusset 20 wherein the length of the seal member 30 extends beyond the length of the tabs 38. Additionally, the seal member 30 is positioned around the opening 26. As shown in FIG. 6, the tabs 38 position between the inside wall 22 of the side gusset 20 and the seal member 30. Once the seal member 30 is properly positioned within the flexible bag 10, the seal member 30 is heat bonded to both the tabs 38 and the inside wall 22 to seal the tabs 38 to the inside wall 22 and to seal the opening 26 (FIG. 7). In one embodiment, the heat sealing includes a heat activated coating compatible with both the flexible bag 10 and the handle assembly 12. Sealing this member 30 insures that the handle assembly 12 securely attaches to the flexible bag 10 and insures integrity of the flexible bag 10 by covering the gusset opening 26. As such, without the seal member 30, the handle assembly 12 would separate where it passes through the opening 26 because the sides of the handle assembly 12 are not bonded together.

The size of the handle assembly 12 and the folding patterns of the fold lines 44 are such that the hand portions 28, when folded flat, are completely enclosed within the side gusset 20 when the flexible bag 10 is folded flat (FIG. 8). The hand portions 28 fold along the fold lines 44 such that the hand portions 28 position within the side gusset 20 when the side gusset 20 collapses to a retracted position. In the retracted position, the side gusset 20 encloses the hand portion 28. The hand portion 28 remains flat against the side gusset 20 when the flexible bag 10 is opened and is filled with the desired content. The user then pulls the hand portion 28 away from the side gusset 20 enabling the handle assembly 12 to be used in an expanded position. In the expanded position, the hand portions 28 extend beyond the side gusset 20.

Since the handle assembly 12 is sealed to the flexible bag 10, the user can easily and effectively pour contents out of the flexible bag 10 while maintaining the integrity of the interface of the handle assembly 12 and the flexible bag 10 (FIG. 9). Furthermore, the sealed handle assembly 12 eliminates edges prone to contamination. The handle assembly 12 allows for convenient pouring out of a variety of heavy and light contents such as but not limited to dry granular products, cereal, flour and soap.

During manufacturing of the handle assembly 12, the manufacturer die-cuts the handle assembly 12 from a film or blank of plastic wherein this film comprises a material strong enough to prevent ripping or tearing. In one embodiment, the manufacturer may dispose a coating on one side of the plastic with the heat activated bonding layer. The manufacturer then forms the hand portion 28 by cutting the bottom and the radius of each finger area 42 from the hand opening 40. Next, the manufacturer forms the gusset opening 26 along the centerfold of at least one of the side gussets 20. Accordingly, the gusset opening 26 may be formed on both sides of the flexible bag 10 or on just one side of the flexible bag 10. The manufacturer may cut the length of the gusset opening 26 to equal the length of the hand portion 28 of the handle assembly 12.

The tabs 38 of the hand portions 28 are then inserted through the gusset opening 26 to position the tabs 38 next to and along the inside wall 22 of the respective side gusset 20. The manufacturer then folds outwardly each tab 38 from the gusset opening 26. These unfolded tabs 38 are then heat sealed to the inside wall 22 of the side gusset 20. The manufacturer then positions the seal member 30 inside the flexible bag 10 in a position opposite the inside wall 22 of the side gusset 20 of the now sealed tabs 38. Once the seal member 30 is properly positioned within the flexible bag 10, the manufacturer heat bonds the seal member 30 to both the tabs 38 and the inside wall 22 and in a configuration around the opening 26.

The manufacturer may then fold the hand portions 28 along the fold lines 44 such that when the hand portions 28 are folded flat, the side gusset 20, in the retracted position, encloses the hand portions 28. In another embodiment, the manufacturer may leave the hand portion 28 protruding from the center of the side gusset 20 when the side gusset 20 folds flat or folds open.

Turning to FIG. 10, in another embodiment of the handle assembly 12 of the present disclosure, the hand portions 28 can be constructed without the flat folding feature (FIG. 8). In this embodiment, the hand portion 28 protrudes from the center of the side gusset 20 when the side gusset 20 folds flat or folds opened. The side gusset 20 extends somewhat beyond the bag edge when the flexible bag 10 is folded flat within the side gusset 20 having a width smaller than 4.25 inches. This embodiment is user-friendly by being readily usable rather than having to manually extend the hand portions 28 as with the folded approach. The seal member 30 still maintains the integrity of the interface of the handle assembly 12 and the flexible bag 10 while eliminating edges prone to contamination.

Still further, in another embodiment of a handle assembly of the present disclosure (not shown), the handle assembly bonds directly to the outside wall of the side gusset. In this embodiment, the tabs bond to the outside wall of the side gusset. As such, this embodiment eliminates slitting the flexible bag and eliminates using any seal member. Accordingly, eliminating these components reduces equipment costs associated with these components to achieve cost savings.

Unlike plastic, paper is more prone to tearing. In addition, many paper bags are constructed with multiple layers. Many products packaged in paper bags have ingredients such as oil that will wick into the paper causing a stain thus having a negative affect on the graphics. The paper has a coating to prevent this from happening. However, contamination will occur through an exposed edge such a handle interface.

A slit in a side gusset of an existing paper bag will weaken the bag structure, since tearing is likely to occur at the ends of the slit. Furthermore, the slit creates raw edges in the paper that may be exposed to the product; thus providing a scenario for contamination. As noted, it is imperative that the paper bag retains a strong construction without any potential areas of contamination.

In another embodiment of the present disclosure (FIG. 11), a flexible bag comprises a paper bag 46 wherein the handle assembly 12 (FIG. 12) is configured to attach to the paper bag 46. The paper bag 46 comprises a rectangular opening 48 defined through the side gusset 20, centered on the centerfold 50 of the gusset 20. The position of the opening 48 is to be determined by the packager to achieve the desired performance.

Turing to FIG. 12, the paper bag 46 further comprises two seal members 52 placed over the opening 48, one on the inside and one on the outside. The seal members 52 are centered over the opening 48 and sized to be larger than the opening 48. The material of the seal members 52 provides strength with resistance to tearing as well as withstanding contamination. In one embodiment, the seal material comprises a plastic laminate with a layer of polyester. Further, each seal member 52 has a layer of heat-seal coating 54 on one side that is compatible with both the inside and outside of the paper bag 46. Once the seal members 52 are in position, the seal members 52 are heat-sealed to the paper bag 46, on both sides, as well as to each other in the area of the opening 48.

The attachment of the seal members 52 to the paper bag 46 and over the opening 48 seals the cut edges of the opening 48. As such, the seal members 52 provide the necessary strength to accept the handle assembly 12 without tearing. Furthermore, the strength of the seal members 52 allow a slit 56 or opening to be positioned through the seal members 52, wherein the slit 56 accepts the handle assembly 12. The seal members 52, coatings 54 and slit 56 are shown in exaggerated form for clarity.

This slit 56 is placed down the center, centered vertically on the seal members 52. The length of the slit 56 is determined by the width of the handle assembly 12. The lengths of the seal members 52 and opening 48 are designed to provide ample length to accept the slit 56 without cutting into the top or bottom edge of the opening 48. The tabs 38 of the hand portions 28 extend through the slit 56 and along the inside wall 22 of the side gusset 20 wherein another seal member 58 seals the tabs 38 to the inside wall 22 and seals the slit 56.

The handle assembly 12 and flexible bag 10 of the present disclosure are cost effective to manufacture while maintaining integrity of the flexible bag 10. The handle assembly 12 is capable of mounting at an optimal position on the flexible bag 10 based on the dispensing requirements and weight of the flexible bag 10. Additionally, the handle assembly 12 is capable of folding within the side gusset 20 wherein the handle assembly 12 remains comfortable to use yet strong enough to handle the weight of the contents.

In view of the above, it will be seen that the several objects of the disclosure are achieved and other advantageous results are obtained. As various changes could be made in the above constructions without departing from the scope of the disclosure, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. 

1. In a package having a front panel, a back panel, a bottom panel and opposing side gussets in which each side gusset has an inside wall and an outside wall, the improvement comprising: an opening defined through at least one of the side gussets; a handle assembly partially positioned within the opening and partially positioned beyond the opening, the handle assembly comprising hand portions, each hand portion having a tab that extends through the opening and along the inside wall of the side gusset; and a seal member positioned on the inside wall of the side gusset and around the opening wherein the seal member seals the tabs to the inside wall of the side gusset and seals the opening.
 2. The improvement of claim 1 wherein the tabs outwardly extend from the opening in opposing directions and along the inside wall of the side gusset.
 3. The improvement of claim 2 wherein the tabs extend along the inside wall at a distance of about 0.25 inches to about 0.75 inches as measured from the opening.
 4. The improvement of claim 3 wherein the tabs extend along the inside wall at a distance of about 0.50 inches as measured from the opening.
 5. The improvement of claim 1 wherein the hand portions each has a fold line.
 6. The improvement of claim 5 wherein the hand portions fold along the fold line such that the hand portions position within the side gusset when the side gusset collapses to a retracted position.
 7. The improvement of claim 6 wherein the side gusset in the retracted position encloses the hand portions.
 8. The improvement of claim 6 wherein each fold line is positioned about 2.25 inches to about 2.75 inches as measured from an end of each hand portion.
 9. The improvement of claim 1 wherein the hand portions extend beyond the side gusset as the side gusset opens to an expanded position.
 10. The improvement of claim 1 wherein each hand portion has a top, the tops of the hand portions being connected to each other.
 11. A package having a front panel, a back panel, a bottom panel and opposing side gussets in which each side gusset has an inside wall and an outside wall, the package comprising: an opening defined through at least one of the side gussets; a handle assembly partially positioned within the opening and partially positioned beyond the opening, the handle assembly comprising hand portions, each hand portion having a tab that extends through the opening and along the inside wall of the side gusset; and a heat seal member positioned on the inside wall of the side gusset and around the opening wherein the heat seal member seals the tabs to the inside wall of the side gusset and the heat seal member seals the opening such that the hand portions fold within the side gusset when the side gusset collapses to a retracted position and the hand portions extend beyond the side gusset when the side gusset opens to an expanded position.
 12. The package of claim 11 wherein the tabs outwardly extend from the opening in opposing directions and along the inside wall of the side gusset.
 13. The package of claim 11 wherein each hand portion has a top, the tops of the hand portions being connected to each other.
 14. A method of attaching a handle assembly to a package having side gussets, comprising: forming an opening in at least one of the side gussets; inserting the handle assembly partially within the opening; extending tabs of the handle assembly beyond the opening and along an inside wall of the side gusset; and sealing the tabs to the inside wall of the side gusset and sealing the opening.
 15. The method of claim 14 wherein sealing the tabs comprises heat bonding the tabs to the inside wall of the side gusset.
 16. The method of claim 15 wherein extending the tabs comprises positioning the tabs along the inside wall of the side gusset.
 17. The method of claim 16 wherein the sealing the tabs further comprises heat bonding a seal member around the tabs and to the inside wall.
 18. The method of claim 17 wherein positioning the tabs along the inside wall of the side gusset comprises positioning the tabs between the seal member and the inside wall. 